Expandable structures for wellbore deployment

ABSTRACT

The subject disclosure relates to expandable structures that seal and block cross-sections of a wellbore. In an embodiment, the apparatus comprises a plurality of structure plates and at least one expandable structure, the apparatus operable to change a perimeter diameter and block a cross-section when deployed.

FIELD

The subject disclosure generally relates to expandable structures for use at a well site. More particularly, the subject disclosure relates to expandable structures which block and seal cross sections of a wellbore.

BACKGROUND

The subject disclosure relates generally to systems that deploy, convey, or otherwise interact with instruments in oilfield operations including, but not limited to, well services, completions, wireline, marine and land seismic jobs, and sub sea oil exploration and the like. The subject disclosure also relates generally to the field of expandable structures which have the ability to block cross sections of cylindrical workspaces for oilfield operations.

Embodiments of the subject disclosure also relate generally to self-supporting structures configured, to expand or collapse, while maintaining their overall shape as they expand or collapse in a synchronized manner. Such structures have been used for diverse applications including architectural uses, public exhibits, and unique folding toys. A basic building block of such structures is a “loop-assembly” that consists of three or more scissor units (described in U.S. Pat. Nos. 4,942,700 and 5,024,031) or polygon-link pairs (described in U.S. Pat. Nos. 6,082,056 and 6,219,974), each consisting of a pair of links that are pinned together at pivots lying near the middle of each link. Such a loop assembly includes a ring of interconnected links that can freely fold and unfold. Structures and methods for constructing such reversibly expandable truss-structures in a wide variety of shapes are described in the above referenced patents. Structures that transform in size or shape have numerous uses. If one desires to have a portable shelter of some kind, it should package down to a compact bundle (tents being a prime example).

SUMMARY

This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

According to some embodiments, an apparatus comprising a plurality of structure plates and at least one reversibly expandable structure operable to change a perimeter diameter is disclosed. The deployed apparatus is operable to block a cross-section when deployed.

According to some further embodiments, a method for blocking a cross-section of a well is disclosed. The method comprises providing an apparatus comprising a plurality of structure plates and at least one reversibly expandable structure and changing the perimeter dimension of the at least one reversibly expandable structure to block a cross-section of the well.

According to some embodiments, a method for blocking a cross-section of a wellbore is disclosed. The method comprises providing an apparatus comprising a plurality of structure plates and at least one reversibly expandable structure and deploying the apparatus to block a cross-section of the wellbore.

According to some further embodiments, a method for blocking a cross-section of a well is disclosed. The method comprises deploying an apparatus comprising a plurality of structure plates and at least one reversibly expandable structure in a collapsed state to a location in a well; and transitioning the apparatus to an expanded state at the location, a level of expansion for the expanded state defined by the wellbore.

Further features and advantages of the subject disclosure will become more readily apparent from the following detailed description when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject disclosure is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of embodiments of the subject disclosure, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein:

FIG. 1 is an embodiment of a well blocking and supporting expandable structure in an expanded or deployed state;

FIG. 2 depicts the internal structure of a well blocking and supporting expandable structure;

FIGS. 3A-3C depict the internal anchoring components of the well blocking and supporting expandable structure;

FIG. 4 is a front view of an embodiment of a given expandable structure in an expanded state accommodating another expandable structure in a collapsed state;

FIG. 5 depicts a well blocking and sealing expandable structure;

FIG. 6 depicts a sealing cloth which has not fully unfolded in a sealing system; and

FIGS. 7A-7C depict details of a sealing cloth unfolding and sealing.

DETAILED DESCRIPTION

The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the subject disclosure only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the subject disclosure. In this regard, no attempt is made to show structural details in more detail than is necessary for the fundamental understanding of the subject disclosure, the description taken with the drawings making apparent to those skilled in the art how the several forms of the subject disclosure may be embodied in practice. Furthermore, like reference numbers and designations in the various drawings indicate like elements.

Embodiments are described with reference to certain techniques, equipment and tools for downhole use. In particular, focus is drawn to methods and devices which are employed at an open-hole well in the form of fixed production tubing and coiled tubing delivery equipment. However, a host of alternate forms of downhole devices and delivery techniques may be employed which take advantage of embodiments of closed loop kinematics mechanisms as detailed herein. Such mechanisms, referred to herein as expandable structures or deployable structures, may also be employed in constructing expandable packers, restrictors, support structures and a host of other oilfield device and deployment uses. Regardless, when deployed downhole in a well, the structure includes linked modules configured to act together dynamically defining an outer diameter thereof based on the diameter of the well.

Embodiments of the subject disclosure comprise a plurality of modules. A first module is adapted to store energy and in one non-limiting example, the energy storage module stores potential energy. In embodiments of the subject disclosure the energy storage module comprises a plurality of linkages arranged around the Z axis. The plurality of linkages may be open and un-deformed in a default position. Each linkage comprises a compliant component arm. The plurality of compliant component arms may deform and reach a minimum diameter around the Z axis. The deformed arms may be placed into a housing module for deployment. In this closed arms state, the system stores potential energy in the deformed arms.

A second module is adapted to change a diameter depending on the engineering requirements. This module is an expandable structure or deployable structure skeleton module with the ability to lock at different diameters. The locking diameter is defined by the inner diameter of the cylindrical workspace where the system is deployed.

A third module is adapted to block the cross-section of a cylindrical workspace. This module comprises a plurality of structure plates. This plurality of structure plates block the cross-section of the cylindrical workspace where the system is deployed. The plurality of structure plates are connected to the linkages of the expandable structure or deployable structure skeleton module. The plurality of structure plates are driven and supported by the members of the deployable structure skeleton module. The plurality of plates may also be used to support sealing material or mechanical components and alternate materials may be contemplated by those skilled in the art and may be utilized in accomplishing the various aspects of the subject disclosure.

A fourth module comprises a plurality of anchoring devices which anchor the system with respect to the workspace where the system is deployed. Each of these anchoring devices is mounted on an edge of a structure plate, and self adjusts to the inner diameter of the cylindrical workspace where the system is deployed. In one non-limiting example the anchoring devices are cams. These cams may use a passive grip, and do not require power to generate radial forces.

A fifth module comprises an actuator for releasing stored energy and a housing module for storing the system before deployment. The system stores energy in an un-deployed state and the stored energy is released when the system deploys. In embodiments of the subject disclosure, potential energy may be stored in the first module which is adapted to store energy. Potential energy is stored as a result of folding of the plurality of the compliant arms. The entire un-deployed system may be stored in a housing, in one non-limiting example a tube structure. To release the system and energy from the housing, in one non-limiting example, an axial actuator pushes the system from the enclosed housing axially. Different types of actuation systems may be used, for example, electromechanical systems, robotic systems, electro hydraulic systems, but other actuation systems are contemplated. Further actuation systems are disclosed in a related patent application U.S. application Ser. No. 11/962,256 entitled System and Methods for Actuating Reversible Expandable Structures, filed on Dec. 21, 2007, the contents of which are herein incorporated by reference. Once the stored energy is released, the system may automatically deploy, self adjust, and anchor with respect to cylindrical spaces, pipes, wells etc. Further, the system may be locked and unlocked at different states of deployment.

The subject disclosure has many applications in both oilfield and non-oilfield related technologies. Embodiments of the subject disclosure may be used to block the cross-section of a space where the system is deployed. Further, once the system is deployed, it can be utilized as a structure on which other elements can be placed and supported. Embodiments of the subject disclosure may support sealing materials placed on top of the system. In further embodiments, the subject disclosure may support sealing materials against the boundaries of the space where the system is deployed in order to seal a passage of fluids across the system. Embodiments of the subject disclosure may isolate sections of a well or other cylindrical environment when used in combination with sealing materials; elastomers, fluid reactive elastomers, and swellable materials are some non-limiting examples of these sealing materials. The system, in this case, keeps the elastomer between for example, a casing or formation and the outer surface of the system, to seal and produce zonal isolation of a well. Embodiments of the subject disclosure may convey sensors outward in a radial direction to a casing or an open-hole formation for purposes of monitoring and preventing fluids from migrating into a main well or pipe.

Referring now to FIG. 1, an embodiment of the subject disclosure is depicted. FIG. 1 depicts an embodiment of a given system (101) in an expanded or deployed state. Embodiments of the subject disclosure have variable and adjustable deployed state cross-sectional areas and perimeters. FIG. 1 depicts an energy storage module (107) which stores energy. The energy storage module (107) comprises a plurality of linkages (113) arranged around the Z axis as depicted in FIG.1. A housing module, in one non-limiting example, a tube (105) may store the energy storage module (107) before deployment. FIG. 1 depicts a plurality of structure plates (109) which provide a surface to block a cross-section of a cylindrical workspace where the system (101) is deployed. The structure plates (109) are connected to a plurality of linkages of the expandable structure or deployable structure skeleton module, which is depicted in FIG. 2. The contour of the structure plates (109) may be chosen based on the geometry you wish to block and the topology of the plates is driven by equations which allow you to optimize the shape. In non-limiting examples, the type of materials chosen for the structure plates depends on the environment where the system is deployed. In non-limiting examples, the materials may be metals, elastomers or polymers. In one non-limiting example, the system (101) is deployed in a housing (111), for example, a cased or open wellbore. The system (101) may comprise one or a plurality of further systems (101) in series to block larger cross-sectional areas. The system (101) may be stacked in series along its axial (Z direction) axis with other similar or different systems. When similar systems are stacked in series, larger cross-sectional areas may be blocked. The system (101) in an expanded or deployed state has sizeable stiffness and strength in the axial(z), tangential(t) and radial(r) directions.

FIG. 2 depicts one embodiment of the expandable structure or deployable structure skeleton module (203) which is adapted to change a diameter depending on the engineering requirements. This module is an expandable structure or deployable structure skeleton module with the ability to lock at different diameters. The locking diameter is defined by the inner diameter of the cylindrical workspace where the system is deployed. FIG. 2 also depicts the plurality of anchoring devices (201) which anchor the system (211) to a housing (205) which in non-limiting examples, is a cased or open-hole wellbore. A plurality of linkages (207) is arranged around the Z axis. The plurality of linkages may be open and un-deformed in a default position. Each linkage comprises a compliant component arm. The plurality of compliant component arms may deform and reach a minimum diameter around the Z axis. The deformed arms may be placed into a housing module (209) for deployment. In this closed arms state, the system stores potential energy in the deformed arms.

FIG. 3A-3C depicts the internal anchoring components of the system. FIG. 3A-3C depicts the energy storage module (301) and a plurality of anchoring devices (303). The plurality of anchoring devices (303) anchors the system with respect to a workspace where the system is deployed. Each of these anchoring devices (303) is mounted on an edge of a structure plate (315), and self adjusts to the inner diameter of the cylindrical workspace where the system is deployed. In one non-limiting example the anchoring devices are cams.

FIG. 3A depicts the plurality of linkages (311) arranged around the Z axis. The plurality of linkages may be open and un-deformed in a default position. Each linkage comprises a compliant component arm. The plurality of compliant component arms may deform and reach a minimum diameter around the Z axis. The deformed arms may be placed into a housing module (307) for deployment. In this closed arms state, the system stores potential energy in the deformed arms. The housing module (307) comprises an outer cylindrical rod (305) which is slideable along the housing module (307) which in a non-limiting example is a cylindrical rod.

FIG. 3B depicts the structure plates (315) and an anchoring device (303). FIG. 3C depicts one of the linkages (311) in the deployable structure connected to another linkage (311) by a regular revolute joint (313) which allows two connecting linkages to rotate with respect to each other. The linkage (311) comprises an anchoring device (303) which in a non-limiting example may be a cam. The anchoring device (303) may be connected to the linkage (311) with a square bracket (309).

FIG. 4 depicts a front view of an embodiment of a given expandable structure or deployable skeleton module in an expanded state accommodating another expandable structure in a collapsed state. Referring now to FIG. 4, embodiments of two expandable structures or deployable skeleton modules (400), (401) are depicted. As detailed further herein the structures 400, 401 are configured to serve as production tubing segments in an open-hole or cased hole wellbore. However, as noted above, such structures (400), (401) may be employed for a host of alternative downhole uses. The structure (400) is in an expanded state, whereas the other (401) is in the collapsed state.

The difference between a structure's expanded and collapsed state is referred to as its expansion ratio. In the embodiment of FIG. 4, the main body of the structures (400), (401) has an expansion ratio that is about 200%-300%. In other words, the fully expanded structure (400) is about twice the size of the collapsed structure (401), in terms of diameter. Indeed, most embodiments for well usage will have an expansion ratio of up to about 300%. However, depending on the circumstances anywhere from about 5% to about 500% may be practical.

Continuing with reference to the expanded structure (400) of FIG. 4, it is made up of modules (425) which are linked together circumferentially. In turn, each module (425) includes forward (450) and rearward (475) members which are pivotally jointed relative to one another through a central pivot. With this in mind, an expansion ratio as described above may be determined. That is, an expansion ratio for a structure of jointed or linked members may roughly be determined by the equation m/nπ, where m is the number of modules 125 and n is the number of pivots in the body of the members 150, 175. Thus, in this case, there are about 9 modules (425) and a single pivot through each member body resulting in an approximate expansion ratio of about 9/(1)(3.14), or 286% (i.e., the 200%-300% noted above).

Of course, each module (425) is also linked to each adjacent module (425) through pivots, (452), (456) at either end thereof. For example, an inner arm pivot (456) connects the arm (455) each forward member (450) to the arm (455) of each rearward member (475). Similarly, adjacent members (450), (475) are linked through an outer abutting pivot (452). With respect to the collapsed structure (401), these same features may be seen upon inspection of members (451) which are oriented in the collapsed position (e.g., revealing internal pivots originating at a truly internal position in advance of structure expansion).

Each module (425) may be equipped with a locking mechanism (470) mounted to each rearward member (475). This mechanism (470) serves as a locking interface between the members (450), (475) so as to ensure maintenance of the expanded state of the structure (400) following synchronized rotation of the members (450), (475) from a collapsed state (such as that of the collapsed structure (401)). Locking mechanisms are further disclosed in related patent application U.S. application Ser. No. 12/713758 entitled “Expandable Structures for deployment in a well,” filed Feb. 26, 2010, the contents of which is herein incorporated by reference. Additionally, in certain embodiments, each structure 400, 401, may be encircled by a compliant material 410, 411 (e.g., about its main body 415, 416).

The compliant layers (410), (411) may be of elastomers or other materials suitable for downhole use, particularly for interfacing and/or sealing engagement with a well wall. Further, each layer (410), (411) may in essence be multilayered in the form of material multi-wrapped about the structure (400), (401) that may unwind or unravel as a structure 401 moves from a collapsed to an expanded state. Thus, the embodiment of FIG. 4, the thickness (d′) of the layer (411) about the collapsed structure (401) is greater than the thickness (d) of the later (410) about the expanded structure. This is due to the noted unraveling, as a layer (410), (411) of a smaller collapsed structure (401) is forced to encompass a larger structure (400). Stated another way, the overall perimeter is greater for the expanded structure (400), and thus, a smaller amount of layering is present in its outer layer (410).

In a related alternate embodiment, the outer layers (410), (411) of the structures (400), (401) may be made of a unitary stretchable sealing material as opposed to the multi-wrapped configuration. Again, the thickness of the material would become thinner as the structures (400), (401) expand. However, in circumstances where the degree of expansion allows for such cohesive and unitary layers (410), (411), such embodiments may be quite practical.

FIG. 5 depicts a further embodiment of the subject disclosure which seals and blocks cross-sections of a cylindrical workspace. FIG. 5 depicts a sealing system (509) which comprises a sealing cloth (505). The cloth (505) is fully unfolded in the completely expanded or deployed system (509). The cloth (505) in embodiments of the subject disclosure blocks fluid (503) from passing from one side to the other of the cross-sectional area the system is blocking which in non-limiting examples may be a cylindrical space, pipe or a well where the system is deployed. In non-limiting examples, the cloth may be made of a sealing material which may comprise elastomers, fluid reactive elastomers or swellable materials. The cloth (505) is disposed adjacent a plurality of structure plates (511) as discussed above. The cloth (505) is attached on several sections to an outer surface of the expandable or deployable structure. In one non-limiting example, the cloth (505) is permanently attached or glued on several sections to an outer surface of the expandable or deployable structure. The sealing system (509) may be deployed in a cylindrical space (501), in a non-limiting example a wellbore. FIG. 5 further depicts additional systems (507) in series which may be used to block larger cross sectional areas.

FIG. 6 depicts a sealing cloth (603) which has not fully unfolded in a sealing system (609) which is completely expanded or deployed. The cloth (603) may block a fluid (601) crossing from one side to the other of a cross-sectional area which the sealing system (609) is blocking The sealing cloth (603) may fold into a counter-bore (605) which may form between a sealing system (609) and any additional components in series (607).

FIG. 7A-7C depicts details of a sealing cloth (705) folded on top of a sealing system (707) and also folded in an annulus (709) between a border of the sealing system (707) and an inner surface (711) of a cylindrical space (703). In embodiments of the subject disclosure the sealing cloth (705) has folds which are designed to prevent over stretching of the sealing cloth (705) which may cause rupturing. These multiple pleated-type folds allow for additional sealing cloth material to be included. Further, the sealing cloth (705) is designed to be squeezed between an edge of the sealing system (707) and an inner surface of a cylindrical space (703). The sealing cloth (705) has different folds at different states of deployment e.g., pre-deployed state, during deployment and in a fully deployed state. FIG. 7A depicts the initial expansion process of the sealing cloth (705) between the outer most surface of the deployable structure (701) and the cylindrical space (703). FIG. 7B depicts the expansion process with the sealing cloth (705) folded between the cylindrical space (703) and the deployable structure (701) with the sealing cloth (705) reaching the inner surface of a cylindrical space (703). FIG. 7C depicts the final expansion process of the sealing cloth (705) with the sealing cloth (705) squeezed between the deployable structure (701) and the cylindrical space (703) resulting in a fluid tight seal.

The expandable structure or deployable structure deploys the sealing cloth (705) towards an inner surface (711) of a cylindrical space (703). The expandable structure or deployable structure anchors the sealing system (707) in the cylindrical space (703) and permits the unfolding of the sealing cloth (705) as the expandable structure or deployable structure deploys towards the cylindrical space (703). Similarly, the expandable structure or deployable structure permits the folding of the sealing cloth (705) as the expandable structure or deployable structure is released and moves away from the cylindrical space (703).

In embodiments, the expandable or deployable structure may be fully deployed but the sealing cloth is not fully stretched. The sealing cloth on top of the expandable structure or deployable structure may have folds. In other embodiments, the sealing system may be fully deployed with the sealing cloth fully unfolded.

Embodiments of the subject disclosure may seal a first section from a second section in a longitudinal axis of a cylindrical space. Further, embodiments of the subject disclosure may isolate a first side of a cylindrical space from a second side of a cylindrical space where the system is deployed. Embodiments of the subject disclosure may isolate sections of a well when used in combination with sealing materials, in non-limiting examples, elastomers, fluid reactive elastomers, and swellable materials. In non-limiting examples, the types of material chosen will depend on wellbore conditions. The system, in this case, would sandwich the elastomers between the casing or formation and the outer surface of the system to seal and produce zonal isolation of a well.

Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wood parts together, whereas a screw employs a helical surface, in the environment of fastening wood parts, a nail and screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words “means for” together with an associated function. 

What is claimed is:
 1. An apparatus comprising: a plurality of structure plates; at least one reversibly expandable structure operable to change a perimeter diameter; and the apparatus operable to block a cross-section when deployed.
 2. The apparatus of claim 1, wherein the plurality of structure plates are connected to the at least one reversibly expandable structure.
 3. The apparatus of claim 2, wherein the plurality of structure plates are driven by the at least one reversibly expandable structure.
 4. The apparatus of claim 1, wherein the perimeter dimension of the at least one reversibly expandable structure is variable, lockable and adjustable.
 5. The apparatus of claim 1, wherein the apparatus is deployed in a wellbore.
 6. The apparatus of claim 5, wherein a plurality of apparatuses are deployed in series along an axial dimension of the wellbore.
 7. The apparatus of claim 4, wherein the perimeter dimension of the at least one reversibly expandable structure is defined by the inner diameter of a wellbore.
 8. The apparatus of claim 1, further comprising an anchoring device.
 9. The apparatus of claim 1, wherein the at least one reversibly expandable structure comprises a plurality of linkages.
 10. The apparatus of claim 9, wherein each linkage comprises a compliant arm.
 11. The apparatus of claim 10, further comprising a housing.
 12. The apparatus of claim 11, wherein the compliant arm in a deformed state is stored in the housing.
 13. The apparatus of claim 12, wherein the compliant arm stores energy in the deformed state.
 14. The apparatus of claim 11, wherein the housing is a tube.
 15. The apparatus of claim 1, further comprising a sealing material.
 16. The apparatus of claim 15, wherein the sealing material is disposed adjacent the plurality of structure plates.
 17. The apparatus of claim 15, wherein the sealing material is attached to the plurality of structure plates.
 18. The apparatus of claim 15, wherein the sealing material has multiple pleated-type folds.
 19. The apparatus of claim 15, wherein the sealing material seals fluid communication from one side to the other of the cross-sectional area when deployed.
 20. The apparatus of claim 15, wherein the sealing material fluidly isolates a first or upper section from a second or lower section of the wellbore.
 21. The apparatus of claim 15, wherein the wellbore is a cased or open hole wellbore.
 22. The apparatus of claim 1, wherein a first section of a wellbore is isolated from a second section when deployed.
 23. The apparatus of claim 15, wherein the deployed apparatus provides zonal isolation along a length of a wellbore.
 24. The apparatus of claim 15, wherein the sealing material is one of an elastomer, a swelling material or combinations thereof
 25. A method for blocking a cross-section of a well comprising: providing an apparatus comprising a plurality of structure plates and at least one reversibly expandable structure; and changing the perimeter dimension of the at least one reversibly expandable structure to block a cross-section of the well.
 26. A method for blocking a cross-section of a wellbore comprising: providing an apparatus comprising a plurality of structure plates and at least one reversibly expandable structure; and deploying the apparatus to block a cross-section of the wellbore.
 27. A method for blocking a cross-section of a well comprising: deploying an apparatus comprising a plurality of structure plates and at least one reversibly expandable structure in a collapsed state to a location in a well; and transitioning the apparatus to an expanded state at the location, a level of expansion for the expanded state defined by the wellbore.
 28. The method of claim 27, wherein the plurality of structure plates block a cross-section when the apparatus is deployed.
 29. The method of claim 27, further comprising a sealing material.
 30. The method of claim 27, wherein the sealing material seals the cross-section when deployed. 